A Review of Backup Mechanism for Reducing Delamination when Drilling Composite Laminates

Over the past decades, composite materials have been increasingly utilized in various industries because of their superior mechanical properties and resistance to corrosion. Drilling is essential to produce precise holes when load-carrying structures are produced using composites. Because of the non-homogeneous and anisotropic property of composite laminates, delamination often occurs at the point where the drill exits, which affects reliability and safety. Some studies present a suppressed mechanism to prevent delamination when drilling composite laminates. The experimental results demonstrate delamination is significantly reduced by various suppressed mechanisms and greater feed rates produce the same level of delamination. The use of special drill geometries and backup has been demonstrated to be more advantageous than the use of adapted feed controls. The basis for the future development of a suppression mechanism for drilling composite laminates is determined

Effect of tool wear on delamination in drilling composite materials

Abstract Among all machining operations, drilling using twist drill is the most frequently applied for secondary machining of composite materials owing to the need for structure joining. Delamination is mostly considered as the principal failure model in drilling of composite materials. Drill wear is a serious concern in hole-making industry, as it is necessary to prevent damage of cutting tools, machine tools and workpieces. The industrial experience shows the worn drill causes more delamination. This paper presents a comprehensive analysis of delamination caused by the drill wear for twist drill in drilling carbon fiber-reinforced composite materials. The critical thrust force at the onset of delamination for worn drill is predicted and compared with that of ideal drill. The experimental results demonstrate that though the critical thrust force is higher with increasing wear ratio, the delamination becomes more liable to occur because the actual thrust force increases to larger extent, as the thrust factor (Z) illustrates. Compared to sharp drill, the worn twist drill allows for lower feed rate below which the delamination damage can be avoided.

Abrasive water jet drilling of advanced sustainable bio-fibre-reinforced polymer/hybrid composites : a comprehensive analysis of machining-induced damage responses

This paper aims at investigating the effects of variable traverse speeds on machining-induced damage of fibre-reinforced composites, using the abrasive water jet (AWJ) drilling. Three different types of epoxy-based composites laminates fabricated by vacuum bagging technique containing unidirectional (UD) flax, hybrid carbon-flax and carbon fibre-reinforced composite were used. The drilling parameters used were traverse speeds of 20, 40, 60 and 80 mm/min, constant water jet pressure of 300 MPa and a hole diameter of 10 mm. The results obtained depict that the traverse speed had a significant effect with respect to both surface roughness and delamination drilling-induced damage responses. Evidently, an increase in water jet traverse speed caused an increase in both damage responses of the three samples. Significantly, the CFRP composite sample recorded the lowest surface roughness damage response, followed by C-FFRP, while FFRP exhibited the highest. However, samples of FFRP and hybrid C-FFRP recorded lowest and highest delamination damage responses, respectively. The discrepancy in both damage responses, as further validated with micrographs of colour video microscopy (CVM), scanning electron microscopy (SEM) and X-ray micro-computed tomography (X-ray μCT), is attributed to the different mechanical properties of the reinforced fibres, fibre orientation/ply stacking and hybridisation of the samples.Peer reviewe

Processing of aluminum-graphite particulate metal matrix composites by advanced shear technology

Copyright @ 2009 ASM International. This paper was published in Journal of Materials Engineering and Performance 18(9) and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this paper for a fee or for commercial purposes, or modification of the content of this paper are prohibited.To extend the possibilities of using aluminum/graphite composites as structural materials, a novel process is developed. The conventional methods often produce agglomerated structures exhibiting lower strength and ductility. To overcome the cohesive force of the agglomerates, a melt conditioned high-pressure die casting (MC-HPDC) process innovatively adapts the well-established, high-shear dispersive mixing action of a twin screw mechanism. The distribution of particles and properties of composites are quantitatively evaluated. The adopted rheo process significantly improved the distribution of the reinforcement in the matrix with a strong interfacial bond between the two. A good combination of improved ultimate tensile strength (UTS) and tensile elongation (e) is obtained compared with composites produced by conventional processes.EPSR

A cutting force model based on kinematics analysis for C/SiC in rotary ultrasonic face machining

Ceramic matrix composites (CMC) superior properties and are used in the harsh conditions of high temperature and pressure, in aerospace and other industries. However, due to inhomogeneous and anisotropic properties of the composites, the machining is still challenging to achieve desired efficiency and quality. For advanced materials, Rotary ultrasonic machining is considered as a process with high efficiency technology. The cutting force is a critical factor required to be effectively predicted and controlled to reduce processing defects in composites. In this research, the rotary ultrasonic machining was used for face machining of carbon reinforced silicon carbide matrix composites (C/SiC), with a conical shaped tool. The kinematics between individual diamond abrasive and the workpiece material was analyzed to illustrate the separation characteristics in the cutting area. The condition for the intermittent machining during RUFM was obtained by establishing the mathematical relation between cutting parameters and vibration parameters. The indentation fracture theory was adopted to calculate the penetration depth into the workpiece by diamond abrasives in the RUFM. The relationship of cutting force and processing parameters including spindle speed, feed rate, and cutting depth were investigated. The comparison of the experimental and simulation data of the cutting force, showed that most of the tests, the errors were below 15 %. It is therefore stipulated that the cutting force model developed in this paper can be applied to predict cutting forces and optimize the process in the RUFM of C/SiC

Proceedings of the Thirteenth International Society of Sports Nutrition (ISSN) Conference and Expo

Meeting Abstracts: Proceedings of the Thirteenth International Society of Sports Nutrition (ISSN) Conference and Expo Clearwater Beach, FL, USA. 9-11 June 201

The application of a turning tool as the electrode in electropolishing

[[abstract]]In the current study, electropolishing using a turning tool as the electrode for several die materials following turning is investigated. The proposed method uses a traveling electrode instead of the mating electrode as in conventional ECM, hence the dimensional error can be controlled more effectively. Further, the method removes a certain limited amount of material, therefore the complex pre-polishing as required in the soakage electropolishing method is eliminated. This process can be used for various turning operations including end turning, form turning, and flute and thread cutting. Through the attachment of simple equipment, electropolishing can follow the cutting on the same machine and chuck. The electrode of the turning tool travels and polishes the machined surface of workpiece with electrical current. Among the factors affecting the electropolishing, the design of tool electrode is discussed primarily. A common turning tool can be used in electropolishing, while a slight modification of tool geometry achieves optimal polishing at low cost. The controlling factors include the chemical composition and concentration of the electrolyte, the initial gap width, and the flow rate of the electrolyte. The experimental parameters are the current rating, the electrode geometry, the die material, the workpiece rotational speed, and the electrode feed rate. Turning tools with larger angles and smaller cross-section are associated with larger discharge space and thus polish better. The most significant factors in tool design for improving the surface roughness include the end clearance angle and the end cutting edge angle. A smaller nose radius is associated with higher current density and provides a faster feed rate and a better polishing effect. © 2002 Elsevier Science B.V. All rights reserved.[[fileno]]2020212010003[[department]]動機

The feasibility analysis of electrical-discharge machining of carbon-carbon composites

[[abstract]]The objective of this research is to investigate the feasibility of using Electrical-Discharge Machining (EDM) for carbon-carbon composite materials as well as the effects of major machining parameters. The material was machined by electrical-discharge sinker using copper electrode. The mechanism of material removal has been revealed by the morphology of debris. The material removal rate, the surface topography and the recast layer that remains on the workpiece surface were studied in terms of EDM processing variables (e.g., pulse current and pulse duration time). The machined surface showing resolidification was examined by Scanning Electron Microscopy (SEM). A qualitative energy dispersive spectroscopic analyzer was used to measure the amount of migrated alloy in the workpiece and the chemical composition of recast layer. The machining damage, the recast layer, and the mass transfer was proportional to the power input. The EDM process is a feasible method for machining of carbon-carbon composites.[[fileno]]2020332010031[[department]]材料